Roofing batten

ABSTRACT

A batten for use in roofing applications is defined by an upside-down U-shaped channel with outwardly projecting horizontal flanges. In certain versions, the legs forming the sides of the channel are asymmetrical to allow vertical orientation of at least one of the legs when installed on an angled roof. This improves strength and load bearing of the installed member, and allows it to provide a fall barrier for roof installers. In certain versions, one of the flanges has a ribbed impact reduction zone. This zone deforms when a building anchor, such as a nail, passes through it to anchor the member to a roof. The deformation prevents anchors fired from conventional equipment from passing completely through the member and holds the anchors more securely in place.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/607,758 filed May 30, 2017 (now U.S. Pat. No. ______), which isincorporated by reference herein.

FIELD OF THE INVENTION

This document relates generally to a building element, namely a battenused in the building of roofs, and in particular a batten made of rolledsteel (or other metal) that may be used with steel (or other metal) orwooden roof trusses.

BACKGROUND OF THE INVENTION

Battens, or purlins, are long, thin, and flat pieces of buildingmaterial that are attached to the roof trusses to which the roofingmaterial is fixed.

In a wooden framed structure, the (often wooden) battens aretraditionally square or rectangular in cross-section. In a steel framedstructure, traditionally the (typically metal) battens each have theshape of a generally U-shaped channel with outwardly extending flanges,wherein each batten is installed inverted (with the channel of the “U”facing downwardly), and with the flanges screwed or otherwise attachedto the roof trusses. The roofing material may then be affixed to thetops of the battens (the generally flat bases of the “U” shape). Thesebattens are often referred to as “top hats”. Top hats may be ofdifferent heights and widths, and the ratio between height and width mayvary, but they are generally symmetrical.

Both top hats and wooden battens are used with both roof tiles and sheetroofing such as corrugated metal roofs. Sheet roofing is generally muchlighter than tiles, and its span is much greater than a tile. A tilegenerally is between 300 mm and 450 mm long, and each row of tiles mustbe supported by a batten, so the battens are spaced 300 mm to 450 mmapart. A piece of sheet roofing can be of almost any length, and thebattens may be spaced at 1200 mm and still provide a strong base for theroof. As a result, many less battens are required to make a roof coveredwith sheet material than tiles. Therefore tiled roofs are much moreexpensive than roofs of sheet material, not only from the cost of tiles,but the cost of battens and the time taken to install so many morebattens.

Most tiles have a lower lip which hooks over the batten and then thetile is nailed to the batten, either through the lip or from the top.

Wooden battens, due to the thickness of the wood, are not very strongand cannot hold the weight of a roof installer. Working at height toinstall a roof means that there is always the risk of falling. Anythingthat can be done to minimise the spaces through which a roof installercan fall is desirable.

A steel batten is much stronger than a wood batten and can help supportthe weight of a worker. (Where this document refers to steel battens, itshould be understood that while steel is preferred, other metals orappropriate plastics might be used instead.) When steel battens areinstalled at a spacing of between 300 and 450 mm, if a worker were toslip, the battens would form a safety net and prevent the worker fromfalling to the ground.

Wooden battens can warp and have weak spots. Steel battens do not warpor suffer from weak spots. However, the strength of a steel batten canbe affected by the shape of the cross section, how it is installed, andthe thickness of the steel used. Steel battens or top hats may beoverlapped at joins due to their shape, providing extra strength. Woodenbattens cannot be overlapped as the roof would then have ridges.

Also, traditional steel battens have not been used with timber trussesand tiled roofs due to higher costs and changes in work practices beingrequired.

However, wooden battens can be attached to the roof with a nail gun, andwith the same nails used to build the roof trusses and the rest of thebuilding frame. For many reasons workers are reluctant to carry too manytools. They are also reluctant, and it is inefficient, to have toexchange tools for different jobs. Ideally, a steel batten would beinstallable using a standard nail gun. However, due to the thickness ofthe material used to make steel battens, a nail gun will blow a nailright through a steel batten, and won't affix the batten to the trussbelow. This applies if the nail is inserted through the horizontal topof the top hat, or the flanges of the top hat. Additionally, traditionaltop hats also have narrow flanges which do not allow the application ofa nail gun at an appropriate angle, limiting the ways in which thebatten may be installed.

Typically, steel battens have been more expensive than timber battensdue to the material used and the working required. Usually a steelbatten is made from 0.55 mm steel. This provides a steel batten strongenough to hold the weight of any roofing material as well as providing afall barrier when installed on the roof trusses. However, at currentprices, a typical steel batten cannot compete cost-wise with woodenbattens. Even the improvements in strength and worker safety do not makea standard steel batten competitive with a wooden batten.

SUMMARY OF THE INVENTION

The invention seeks to provide an improved steel batten which providesat least the same strength as the traditional steel batten made from0.55 mm steel, but uses less steel to do so, providing cost andenvironmental benefits. The invention also seeks to provide a steelbatten which can be used on wooden structures to overcome the safety,strength, and uniformity issues associated with wooden battens.Additionally, it would be advantageous if such a solution avoidedincreased expense or the changes in work practices required by using atraditional steel batten on wooden trusses. The batten must also meetbuilding standards for strength of a steel batten.

The steel batten is preferably made from thinner steel, or uses anarrower width of steel. There are limits on minimum heights and widthsfor a batten to be useful. The most preferred version of the inventionseeks to provide the desired strength not by merely altering thethickness of material, but by changing the design and shape of thebatten. However, slightly different dimensions may result in anessentially similar shape and strength if a different thickness of steelis employed. Furthermore, the invention is not limited by the thicknessof the material used. The thicker the material used, the stronger thebatten of the invention.

A preferred version of the invention involves a batten formed by anupside-down U-shaped channel with outwardly projecting horizontalflanges. In certain versions of the invention, the legs forming thesides of the channel are asymmetrical to allow vertical orientation ofat least one of the legs when installed on an angled roof. This improvesstrength and load bearing of the installed member, even if it does notuse conventional 0.55 mm steel, and allows it to provide a fall barrierfor the roof installers. In certain versions of the invention, one ofthe flanges has a ribbed impact reduction zone. This zone deforms when abuilding anchor, such as a nail, passes through it to anchor the memberto a roof. The deformation prevents anchors fired from conventionalequipment, such as a nail gun, from passing completely through themember and holds them in place more securely.

BRIEF DESCRIPTION OF DRAWINGS

Exemplary versions of the invention will be discussed with reference tothe accompanying drawings wherein:

FIG. 1 is a cross-sectional view of a preferred version of theinvention.

FIG. 2 is a top view of a preferred version of the invention.

FIG. 3 is a left-hand side view of a preferred version of the invention.

FIG. 4 is a right-hand side view of a preferred version of theinvention.

FIG. 5 is a perspective view of a preferred version of the invention.

FIG. 6 is a bottom view of a preferred version of the invention.

FIG. 7 is a perspective view of a preferred version of the inventioninstalled as part of a pitched roof.

In the following description, like reference characters designate likeor corresponding parts throughout the figures.

DETAILED DESCRIPTION OF EXEMPLARY VERSIONS OF THE INVENTION

Referring to FIG. 1, a batten 1 has a horizontal top 2 connecting afirst leg 3 and a second leg 4, resulting in a channel with anupside-down U-shaped cross-section. First leg 3 is at a first internalangle 9 to horizontal top 2, while second leg 4 is at a second internalangle 10 to horizontal top 2. Flange 5 extends substantiallyhorizontally outward from the end of first leg 3 opposite horizontal top2. Flange 6 extends substantially horizontally outward from the end ofsecond leg 4 opposite horizontal top 2. Flanges 5 and 6 also featureturn ups 7 at their free ends. FIG. 1 also shows a vertical axis ofbatten 1 extending from A to A′.

A preferred version of the invention utilizes a first inclined leg 3 anda second substantially vertical leg 4. Another preferred version of theinvention utilizes a ribbed flange 5 and a flat flange 6, with ribbedflange 5 featuring an impact reduction zone 8.

The preferred version of the invention is made of steel. In certainversions of the invention, the steel is a light gauge steel (i.e.,thinner than 24 gauge). In certain versions of the invention, firstinternal angle 9 is an angle of at least 105° or at least 115° withhorizontal top 2. Second internal angle 10 is an angle of at least 92°with horizontal top 2. In certain versions of the invention, the totalheight of batten 1 is no more than approximately 25 mm and the totalwidth of batten 1 is no more than approximately 60 mm.

In one preferred version of the invention, shown in FIGS. 1 through 6,batten 1 is asymmetrical about the vertical axis, i.e., each of the legshas a different length and angle to the other. The specific lengths ofhorizontal top 2, inclined leg 3, and substantially vertical leg 4 canbe altered, but the asymmetrical nature of batten 1 of the invention ispreferred. The asymmetric shape allows attachment of batten 1 withflange 5 on the lower side of batten 1 to align the substantiallyvertical leg 4 to a position that is optimal for engagement with a rooftile. A top downwardly extending lip of the roof tile engagessubstantially vertical leg 4 in such a way that the tile can then beeasily, permanently attached to batten 1. Batten 1 provides a smoothsurface over which the tile lip can be hooked, allowing the tile to stayin place until anchored to batten 1.

The asymmetric shape also means that when installed to angled roofmembers, such as wooden or steel trusses on a pitched roof, both legs ofbatten 1 end up being almost vertical with respect to the ground. Thisaligns both legs with the direction of gravity and helps to provideimproved strength and load bearing. As a result, batten 1 is strongenough to provide a fall barrier for roof installers. Typical roofs havea pitch of approximately 15-30°; during installation, when the shorterside (substantially vertical leg 4) is placed on the higher side of theroof, the longer side (inclined leg 3) will be close to vertical. Thiscompares to traditional battens where the legs are of the same lengthand at the same angle to the horizontal top.

The improved strength of batten 1 means it can be used as a batten ortop hat on any roof member, spaced appropriately for any roofingmaterial, such as, but not limited to, tiles or sheet metal, and stillprovide a fall barrier for the roofing contractors or a place to standwhile the roofing material is installed. The strength of batten 1 meansit is strong enough to meet all appropriate standards for roofingbattens and can carry the loads of roofing material, even the heavyweight of a concrete tile roof.

The exact internal angles and length of the legs may be adjusted tooptimize the alignment of the longer leg for different roof pitches. Thecost of retooling the roll forming machine that makes the battens mayincrease expenses, but if a manufacturer always made roofs with the samepitch, the variations could be worked out to provide the optimalarrangement for that roof pitch. The values used in the version shownare most useful for roofs with pitches of 20-30°, which are common inAustralia, but could be customized to roof pitches ranging from 4° to55°.

Other preferred versions of the invention with ribbed flange 5, as shownin FIGS. 1 through 6, allow batten 1 to be installed on the wooden rooftrusses using a standard building anchor, such as a nail projected froma nail gun. Ribbed flange 5 incorporates at least two ribs; thepreferred version of batten 1 has three ribs. The width of ribbed flange5 can be altered, but is preferably wide enough to allow a nail gun tobe placed in such a way to insert a nail. Ribbed flange 5 also has turnup 7 of at least 90° at its distal end. The preferred version has a turnup 7 of at least 110°.

The ribbing (which may also be called rippling, striations, ridges orundulations) strengthens the material of batten 1 and helps to keep thebuilding anchor in batten 1. The ribbing also forms impact reductionzone 8, allowing the energy in a projected building anchor to bedissipated or absorbed and thereby reducing its impact. As a result, theinstallers may not need to have extra tools or significantly adjust oralter their standard tools and practices of the trade. Furthermore, theforce of the building anchor being installed deforms the ribs in such away that the material folds over and covers the head of the buildinganchor, holding the building anchor more securely and strongly in arecess, and aiding the connection between building anchor, batten, androof member.

The added feature of ribbed flange 5 means batten 1 can be easilyinstalled on either a steel or wooden frame set of roof members, such astrusses. When it is used on wooden framed roof trusses, roofingcontractors do not need to change equipment or alter their roofingpractices. As one example, a nail gun can still be used to attach batten1, and the nail will not pass through the material of flange 5 of batten1.

In versions of batten 1 using ribbed flange 5, flat flange 6 has no ribsand is not as wide as ribbed flange 5. Flat flange 6 also has turn up 7of at least 90° at its distal end. The preferred version has a turn up 7of at least 110°.

As shown in FIG. 7, during installation a user would place batten 1 ontop of at least one roof member, such as, but not limited to, a truss.If batten was asymmetrical and the roof member an angled roof member,the user would orient the batten such that the substantially verticalleg was located further up the angled roof member. The user would thenproject at least one building anchor, such as a nail from a nail gun,partially through flange 5 and into the roof member to connect the roofmember and batten 1. If batten 1 included impact reduction zone 8 withdeformable ribs, the user would project the building anchor partiallythrough impact reduction zone 8 such that the building anchor deformedat least one of the deformable ribs. Once batten 1 was secured, the usercould cover batten 1 with roofing material, such as sheet metal orroofing tile, and project at least one additional building anchorpartially through the roofing material and into the horizontal top tosecure the roofing material to batten 1.

Batten 1 of the invention may also be useful in other areas. Batten 1may be useful for being a support for solar panels, satellite dishes, orother objects mounted on roofs. Any version of batten 1 may also be partof a roof system including at least one roof member, and at least onebuilding anchor partially extending through flange 5 and into the roofmember to connect the roof member and batten 1. The building anchor maybe a nail from a nail gun, while the roof member may be an angled truss,or a wooden or steel roof member.

Throughout this document, unless the context requires otherwise, thewords “include” and “including” (and variations such as “comprise” and“comprising”) will be understood to include the stated element (or groupof elements), as well as additional instances of the stated element (orgroup of elements).

It should also be understood that various terms referring to orientationand position used throughout this document—e.g., “horizontal top”—arerelative terms rather than absolute ones. In other words, it should beunderstood (for example) that the horizontal top referred to may in factbe located at a non-horizontal angle, or at the bottom of the batten,depending on the overall orientation of the apparatus. Thus, such termsshould be regarded as words of convenience, rather than limiting terms.

Where a measurement or other value is qualified by the term“approximately,” “about,” or like terms—for example, “approximately 50mm”—this can be regarded as referring to a variation of 10% from thenoted value. Thus, “about 50 mm” can be understood to mean between 45and 55 mm.

The versions of the invention described above are merely exemplary, andthe invention is not intended to be limited to these versions. Rather,the scope of rights to the invention is limited only by the claims setout below, and the invention encompasses all different versions thatfall literally or equivalently within the scope of these claims.

1. A batten including: a. a channel having a cross-section including:(1) a top surface extending: i. along a top surface plane, and ii.between a first top surface edge and a second top surface edge, (2) afirst leg descending at a first internal angle from the first topsurface edge to a first leg lower edge, (3) a second leg descending at asecond internal angle from the second top surface edge to a second leglower edge, b. a first flange extending outwardly from the channel: (1)from the first leg lower edge to a first flange free end, and (2) alonga plane parallel to the top surface plane; c. a second flange extendingoutwardly from the channel: (1) from the second leg lower edge to asecond flange free end, and (2) along a plane parallel to the topsurface plane.
 2. The batten of claim 1 wherein a. the first internalangle is: (1) greater than 90 degrees, but (2) more perpendicular withrespect to the top surface than parallel, b. the second internal angleis: (1) approximately perpendicular with respect to the top surface, and(2) less than the first internal angle.
 3. The batten of claim 2 whereinthe distance from the horizontal top to the first leg lower edge isgreater than distance between the horizontal top to the second leg loweredge.
 4. The batten of claim 3 wherein the first and second flangesextend along a common plane.
 5. The batten of claim 4 wherein the commonplane is parallel to the top surface plane.
 6. The batten of claim 3wherein the first flange has deformable ribs thereon.
 7. The batten ofclaim 6 wherein the distance from the first leg lower edge to the firstflange free end is greater than the distance from the second leg loweredge to the second flange free end.
 8. The batten of claim 1 wherein thechannel is asymmetrical about an axis perpendicularly bisecting the topsurface plane.
 9. The batten of claim 8 wherein the first flangeincludes ribs thereon, the ribs being defined by upward and downwardbends in the first flange as the first flange extends outwardly from thechannel.
 10. The batten of claim 9 wherein the distance from the firstleg lower edge to the first flange free end is greater than the distancefrom the second leg lower edge to the second flange free end.
 10. Thebatten of claim 11 wherein the first and second flanges extend along acommon plane.
 11. The batten of claim 1 wherein: a, the first internalangle is at least 105°, b. the second internal angle is at least 92°, c.the first and second flanges extend along a common plane orientedparallel to the top surface plane.
 12. The batten of claim 11 whereinthe first flange has deformable ribs thereon, the deformable ribs beingdefined by zig-zagging bends in the first flange.
 13. The batten ofclaim 12 wherein: a. the first flange has a turn up of at least 90° atits first flange free end, and b. the second flange has a turn up of atleast 90° at its second flange free end.
 14. The batten of claim 1wherein the batten is integrally formed as a unitary piece of sheetsteel having 24 gauge or less.
 15. A batten including: a. a channelhaving an upside-down U-shaped cross-section, the channel including: (1)a horizontal top surface, (2) a first leg descending at a first internalangle from the horizontal top to a first leg lower edge, and (3) asecond leg descending at a second internal angle from the horizontal topto a second leg lower edge, wherein: i. the second internal angle isless than the first internal angle, and ii. the distance between thehorizontal top to the second leg lower edge is less than the distancefrom the horizontal top to the first leg lower edge; b. a first flangeextending horizontally outwardly from the first leg lower edge, thefirst flange having multiple deformable ribs thereon; and c. a secondflange extending horizontally outwardly from the second leg lower edge.16. The batten of claim 15 wherein the channel is asymmetrical about avertical axis bisecting the top surface.
 17. The batten of claim 15wherein the first and second flanges extend along a common horizontalplane.
 18. The batten of claim 15 wherein the first and second flangesinclude turn-ups at their free edges.
 19. A batten including: a. achannel having an upside-down U-shaped cross-section, the channelincluding: (1) a horizontal top surface, (2) a first leg descending at afirst internal angle from the horizontal top to a first leg lower edge,and (3) a second leg descending at a second internal angle from thehorizontal top to a second leg lower edge, wherein the second internalangle is: i. at least 92°, and ii. less than the first internal angle;b. a first flange extending horizontally outwardly from the first leglower edge; and c. a second flange extending horizontally outwardly fromthe second leg lower edge, wherein the first and second flange extendalong a common horizontal plane.
 20. The batten of claim 19 wherein thefirst flange has deformable ribs thereon, the deformable ribs beingdefined by zig-zagging bends in the first flange.